Safety Procedure for Valve Replacement and Leak Detection on a Tank Car

ABSTRACT

Aspects of the invention include methods and systems for a testing mechanism to be utilized when repairing and replacing a valve utilized on a tank car. The testing mechanism may comprise a pipe plug device configured to plug a siphon pipe located on a tank car and a pressure test device to conduct a leak detect test after the pipe plug device is removed from the siphon pipe. The pipe plug device may include a pipe plug bladder and a pipe plug pressure fitting to inflate and deflate the pipe plug bladder against a wall of the siphon pipe. The pressure test device may include a pressure test valve cap with a test valve bladder located on the pressure test valve cap, a bladder pressure fitting to inflate and deflate the test valve bladder, and a test pressure fitting to pressurize a valve, the test pressure fitting located on the pressure test valve cap.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/658,744, filed Oct. 21, 2019, which is a continuation of U.S. patentapplication Ser. No. 15/080,185, filed Mar. 24, 2016, which claimspriority to U.S. Provisional Patent Application No. 62/139,474, filedMar. 27, 2015, all of which are herein incorporated by reference intheir entirety.

BACKGROUND

Transporting commodities by common rail carrier is one of the mosteconomical and efficient means to move commodities to destination pointsacross North America. Some railcars transport certain commodities thatare toxic and dangerous, such as petroleum crude oil type products,ethyl alcohol type products, and fuel ethanol type products. Forexample, inhalation of petroleum crude oil vapors may cause centralnervous system problems including headaches, drowsiness, and nausea andmay lead to unconsciousness or death. Additionally, petroleum crude oilmay cause respiratory and eye irrigation, as well as prolonged orrepeated skin contact can result in irritation and dermatitis. Further,petroleum crude oil contains Benzene, a confirmed carcinogen.Additionally, for example, high vapor concentrations of ethyl alcoholand/or fuel ethanol may cause nose, throat, and eye irritation. Theethyl alcohol and/or fuel ethanol may contain toxic denaturants, whereinexposure may lead to headache, drowsiness, nausea, dizziness, andvomiting. Inhalation of concentrations of ethyl alcohol and/or fuelethanol above 5,000 PPM may cause transient eye and nose irritation withcoughing. Skin contact with ethyl alcohol and/or fuel ethanol may resultin drying and cracking due to defatting and hazardous amounts may beabsorbed through severely abraded skin and be irritating to the eyes.Tank cars carrying any of these commodities or any other toxic ordangerous commodities must be treated with care and safety during alloperations, to include maintenance, repair, and replacement activities.

Railroad tank cars are often equipped with valves used for top loadingand unloading of tank cars. These valves are generally attached to thetop fittings flange by NPT threads. The top side of the valve issupplied with another NPT connection. The valve is supplied completewith a handle. These valves must be periodically repaired and/orreplaced.

When these valves must be repaired and/or replaced, generally, nitrogengas or compressed air may be used to leak test the newly installedvalves on the tank cars. The nitrogen gas or compressed air may be usedto pressurize the entire tank car to ensure the newly installed valveson the tank cars are leak proof. This method of using nitrogen gas orcompressed air to pressurize the entire tank car can take a significantamount of time, such as 30-60 minutes per valve or tank. Additionally,nitrogen gas can be expensive or costly, costing as much as $600-$800per tank car per leak test.

A need therefore exists for an improved procedure and testing mechanismfor the valve replacement and leak detection on a tank car.

SUMMARY OF THE INVENTION

The following presents a general summary of aspects of the invention inorder to provide a basic understanding of the invention and variousfeatures of it. This summary is not intended to limit the scope of theinvention in any way, but it simply provides a general overview andcontext for the more detailed description that follows.

According to aspects of this invention, a testing mechanism to beutilized when repairing and replacing a valve utilized on a tank car,the testing mechanism may comprise a pipe plug device and a pressuretest device. The pipe plug device may be configured to plug a siphonpipe located on a tank car. The pipe plug device may include a pipe plugbladder and a pipe plug pressure fitting to inflate and deflate the pipeplug bladder against a wall of the siphon pipe. When the pipe plugbladder is deflated, the pipe plug bladder is sized to fit and slideinside the siphon pipe. When the pipe plug bladder is inflated, the pipeplug bladder is sized to expand and tighten against the wall of thesiphon pipe. The pressure test device may conduct a leak detect testafter the pipe plug device is removed from the siphon pipe. The pressuretest device may include a pressure test valve cap with a test valvebladder located on the pressure test valve cap, a bladder pressurefitting to inflate and deflate the test valve bladder, and a testpressure fitting to pressurize a valve, the test pressure fittinglocated on the pressure test valve cap.

Additionally, another aspect of this invention may relate to a testingmethod comprising the steps of: 1) remove a valve cap from a first valvelocated on a tank car; 2) open the first valve; 3) insert and flownitrogen gas into a siphon pipe located on the tank car below the firstvalve; 4) place a pipe plug bladder through the first valve, wherein thepipe plug bladder is located below the bottom of the first valve andagainst a wall of the siphon pipe; 5) apply a bladder pressure to thepipe plug bladder to inflate the pipe plug bladder to tighten the pipeplug bladder against the wall of the siphon pipe; 6) remove the firstvalve and replace the first valve with a second valve, wherein thesecond valve is installed in an open position; 7) deflate the pipe plugbladder and remove the pipe plug bladder from the second valve and thesiphon pipe; 8) insert a pressure test device into the second valve,wherein the pressure test device includes a pressure test valve cap witha test valve bladder located on the pressure test valve cap, a bladderpressure fitting to inflate and deflate the test valve bladder, and atest pressure fitting to pressurize a valve; 9) apply the bladderpressure to the test valve bladder to inflate the test valve bladder totighten the test valve bladder against the wall of the siphon pipe; 10)apply a test pressure through the pressure test valve cap; 11) conduct abubble leak inspection of the valve; 12) release the test pressure; 12)deflate the test valve bladder; and remove the pressure test device.

Additionally, another aspect of this invention may relate to a safetymethod for valve replacement and leak detection on a tank care, themethod may comprise the steps of: 1) open a first valve located on atank car; 2) insert a pipe plug device through the first valve, whereinthe pipe plug device includes a pipe plug bladder and a pipe plugpressure fitting to inflate and deflate the pipe plug bladder against awall of a siphon pipe, wherein when the pipe plug bladder is deflated,the pipe plug bladder is sized to fit and slide inside the siphon pipeand when the pipe plug bladder is inflated, the pipe plug bladder issized to expand and tighten against the wall of the siphon pipe, andfurther wherein the pipe plug bladder is located below the bottom of thefirst valve and against a wall of the siphon pipe; 3) apply a bladderpressure to the pipe plug pressure fitting to inflate the pipe plugbladder to tighten the pipe plug bladder against the wall of the siphonpipe; 4) remove the first valve and replace the first valve with asecond valve, wherein the second valve is installed in an open position;5) deflate the pipe plug bladder and remove the pipe plug bladder andthe pipe plug device from the second valve and the siphon pipe; 6)insert a pressure test device into the second valve, wherein thepressure test device includes a pressure test valve cap with a testvalve bladder located on the pressure test valve cap, a bladder pressurefitting to inflate and deflate the test valve bladder, and a testpressure fitting to pressurize a valve, the test pressure fittinglocated on the pressure test valve cap; 7) apply the bladder pressure tothe bladder pressure fitting to inflate the test valve bladder totighten the test valve bladder against the wall of the siphon pipe; 8)apply a test pressure through the pressure test valve cap; 9) conduct abubble leak inspection of the valve; 10) release the test pressure; 11)deflate the test valve bladder; and 12) remove the pressure test device.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete understanding of the present invention and certainadvantages thereof may be acquired by referring to the followingdetailed description in consideration with the accompanying drawings, inwhich:

FIG. 1 is a view of a pipe plug bladder device in accordance with anembodiment of the present invention;

FIG. 2 is a view of the pipe plug bladder device of FIG. 1 being left inplace during the removal and installation of valves in accordance withan embodiment of the present invention;

FIG. 3 is another view of the pipe plug bladder device of FIG. 1 beingremoved from the valve in accordance with an embodiment of the presentinvention;

FIG. 4 is a view of a pressure test device in accordance with anembodiment of the present invention;

FIG. 5 is another view of the pressure test device of FIG. 4 inaccordance with an embodiment of the present invention;

FIG. 6 is a view of the pressure test device of FIG. 4 being droppedinto the replacement valve in accordance with an embodiment of thepresent invention;

FIG. 7 is a close-up view of the top of the pressure test device of FIG.4 installed in the valve in accordance with an embodiment of the presentinvention;

FIG. 8 is another close-up view of the top of the pressure test deviceof FIG. 4 installed in the valve in accordance with an embodiment of thepresent invention;

FIG. 9 is a view of the pressure test device of FIG. 4 installed in thevalve in accordance with an embodiment of the present invention; and

FIGS. 10 and 11 are views of a pressure system for providing thepressure to the pipe plug bladder device and the pressure test device inaccordance with an embodiment of the present invention.

The reader is advised that the attached drawings are not necessarilydrawn to scale.

DETAILED DESCRIPTION OF EMBODIMENTS

In the following description of various examples of the invention,reference is made to the accompanying drawings, which form a parthereof, and in which are shown by way of illustration various examplestructures, systems, and steps in which aspects of the invention may bepracticed. It is to be understood that other specific arrangements ofparts, structures, example devices, systems, and steps may be utilizedand structural and functional modifications may be made withoutdeparting from the scope of the present invention. Also, while the terms“top,” “bottom,” “front,” “back,” “side,” and the like may be used inthis specification to describe various example features and elements ofthe invention, these terms are used herein as a matter of convenience,e.g., based on the example orientations shown in the figures. Nothing inthis specification should be construed as requiring a specific threedimensional orientation of structures in order to fall within the scopeof this invention.

A testing mechanism may be utilized when repairing and/or replacing avalve 10 utilized on a tank car. The testing mechanism may include apipe plug device 100 and a pressure test device 200. Generally, the pipeplug device 100 may be utilized to plug and block a siphon pipe 20 aspart of a tank car in order to change and/or replace a valve 10 on thetank car. After the existing valve 10 is replaced with a replacementvalve 30, the pipe plug device 100 may be removed and the pressure testdevice 200 may then be installed. Generally, the pressure test device200 may be utilized to conduct a bubble leak detect test on thereplacement valve 30 fittings.

As illustrated in FIGS. 1-3, the pipe plug device 100 may include a pipeplug bladder 110 and a pipe plug pressure fitting 112 to inflate/deflatethe pipe plug bladder 110. The pipe plug bladder 110 may be sized to fitand slide inside the siphon pipe 20 when deflated. The pipe plug bladder110 may be sized to expand and tighten against the siphon pipe wall 20when the pipe plug bladder 110 is inflated. The pipe plug bladder 110may be inflated with approximately 40 psig, or any other similarpressure to ensure that the pipe plug bladder 110 is tightened againstthe siphon pipe wall 20.

The pipe plug device 100 may also include a rubber hose 114 thatconnects the pipe plug bladder 110 and the pipe plug pressure fitting112. The length of the hose 114 may be approximately 9 inches or othervarious lengths without departing from this invention. The pipe plugdevice 100 may also include a “T” handle 116 that is shaped to spanacross the opening of the valve 10. The “T” handle 116 may include achain 118 that connects to the “T” handle 116 and the pipe plug bladder110 to ensure that the pipe plug bladder 110 is not dropped or lost inthe tank car. The length of the chain 118 may be approximately 9 inchesor other various lengths without departing from this invention.

As illustrated in FIGS. 4-9, the pressure test device 200 may include apressure test valve cap 202 with a test valve bladder 210, a bladderpressure fitting 212 to inflate/deflate the test valve bladder 210, anda test pressure fitting 220 to pressurize the body of the valve 30. Thetest valve bladder 210 may be sized to fit and slide inside the siphonpipe 20 when deflated. The test valve bladder 210 may be side to expandand tighten against the siphon pipe wall 20 when the test valve bladder210 is inflated. The test valve bladder 210 may be inflated withapproximately 40 psig, or any other similar pressure to ensure that thetest valve bladder 210 is tightened against the siphon pipe wall 20. Thebladder pressure fitting 212 may be located on the pressure test valvecap 202. The test pressure fitting 220 may be located on the pressuretest valve cap 202.

The pressure test device 200 may also include a rubber hose 214 thatconnects the test valve bladder 210 and the bladder pressure fitting212. The length of the hose 214 may be approximately 9 inches or othervarious lengths without departing from this invention. The pressure testdevice 200 may also include a chain 218 that connects the bottom of thepressure test cap 202 and the test valve bladder 210 to ensure that thetest valve bladder 210 is not dropped or lost in the tank car. Thelength of the chain 218 may be approximately 9 inches or other variouslengths without departing from this invention.

Described below is a detailed description of additional aspects of thisinvention, specifically a method of leak testing an installed valve 30on a tank car or rail car. Additional aspects of this disclosure relateto methods of replacing a valve 10 on a residue tank car containing atoxic commodity in accordance with examples of this disclosure. Suchmethods may include, for example, one or more of the following steps inany desired order and/or combinations as explained below.

The first step includes removing the valve cap from the existing valve10 using non-sparking tools and opening the existing valve 10.Immediately following the removal of the valve cap and opening theexisting valve 10, the next step may be to insert and flow nitrogen gasinto the siphon pipe 20 for a set amount of time, such as for 60seconds. This flow of nitrogen gas into the siphon pipe 20 creates abarrier and helps to not allow the toxic fumes or commodity to escapefrom the tank car.

Following the flowing of nitrogen gas into the siphon pipe 20, the nextstep is placing the pipe plug bladder 110 through the open valve 10 andapplying a bladder pressure of nitrogen gas to the pipe plug bladder 110to tighten the pipe plug bladder 110 against the siphon pipe wall 20.The bladder pressure may be regulated for example 40 psig or any othersimilar pressure to ensure that the pipe plug bladder 110 is tightenedagainst the siphon pipe wall 20. Additionally, the pipe plug bladder 110should be located just below the bottom of the valve 10 and against thesiphon pipe wall 20.

After the pipe plug bladder 110 is tightened and pressurized against thesiphon pipe wall 20, a measurement of the toxicity levels may be takento ensure that the pipe plug bladder 110 is tightened adequately enough.For example, allowing 60 seconds and measuring the LEL readings within 2feet of the valve 10. A gas detection meter may be utilized to measurethe toxicity level or LEL reading. The gas detection meter may remainwithin 2 feet of the valve 10 to continuously monitor for LEL/LFL beingless than 10% (generally—a 10% to 20% reading requires supplied airrespirator with hip escape bottle).

The next step may be removing the valve 10 with a non-sparking wrenchand replacing the valve 10 with an approved replacement valve 30. Thereplacement valve 30 should be installed in the open position with thecap plug removed. The replacement valve 30 may slide over the bladderchain “T” handle and hose. Once installed on the tank car, thereplacement valve 30 may be tightened on the tank car.

After the replacement valve 30 is installed and tightened on the tankcar, the next step is deflating the pipe plug bladder 110 and removingthe pipe plug bladder device 110 from the replacement valve 30 and thesiphon pipe 20. The pipe plug bladder 110 can be deflated at thepressure fitting 112 utilized to add/release the pipe plug bladderpressure.

Following the removal of the pipe plug bladder device 100, the next stepis inserting the pressure test device 200 into the replacement valve 30.The pressure test valve cap portion 200 of the pressure test device 200will screw into the NPT threads on the top portion of the replacementvalve 30. The pressure test device 200 may be screwed and tightened ontothe NPT threads on the top portion of the replacement valve 30. Afterthe pressure test device 200 is tightened onto the replacement valve 30,the next step is inflating the test valve bladder 210. The test valvebladder 210 may be inflated with nitrogen gas through the valve capbladder fitting 212. The test valve bladder 210 may be inflated to atest bladder pressure, for example 40 psig, or any other similarpressure to ensure that the test valve bladder 210 is tightened againstthe siphon pipe wall 20. Additionally, the test valve bladder 212 shouldbe located just below the bottom of the valve 30 and against the siphonpipe wall 20.

After the test valve bladder 212 is inflated and tightened against thesiphon pipe wall 20, the next step is applying pressure through thepressure test valve cap fitting 220. The valve hose pressure may bereset to a lower pressure, such as approximately 30 psig. The pressuremay be applied from the valve hose pressure and the pressure regulatorthrough the pressure test valve cap fitting 220 to a test pressure, forexample 30 psig, or any other similar pressure to conduct the bubbleleak inspection.

After the pressure is applied through the pressure test valve capfitting 220, the next step is conducting a bubble leak inspection of thevalve threading 32. As illustrated in FIG. 8, the bubble leak inspectionof the valve threading 32 may include utilizing leak or bubble liquid 40on the valve threading 32. If there is leakage at the valve threading32, the liquid 40 will bubble at the valve threading 32. If there is nobubbling at the valve threading 32, there is no leakage at the valvethreading 32. The test pressure may be maintained at the test pressurelevel, such as 30 psig throughout the test.

After the test is complete, the test pressure may be released first andthen release the test bladder pressure. If the pressure test valve cap202 is difficult to remove following the test pressure and test bladderpressure being released, the operator should stop and ensure the bladderpressure is released. Removing the pressure test valve cap 202 with thetest valve bladder 212 under pressure may damage the pressure testdevice 200 or the replacement valve 30.

The pressure test device 200 may then be removed with a non-sparkingwrench and pulling out the pressure test bladder 210 from thereplacement valve 30. The replacement valve 30 may then be closed andthe replacement valve cap may then be reapplied.

It is to be understood that the invention is not limited in itsapplication to the details of construction and the arrangement of thecomponents set forth herein. The invention is capable of otherembodiments and of being practiced or being carried out in various ways.Variations and modifications of the foregoing are within the scope ofthe present invention. It should be understood that the inventiondisclosed and defined herein extends to all alternative combinations oftwo or more of the individual features mentioned or evident from thetext and/or drawings. All of these different combinations constitutevarious alternative aspects of the present invention. The embodimentsdescribed herein explain the best modes known for practicing theinvention and will enable others skilled in the art to utilize theinvention.

While the preferred embodiments of the invention have been shown anddescribed, it will be apparent to those skilled in the art that changesand modifications may be made therein without departing from the spiritof the invention, the scope of which is defined by this description.

What is claimed is:
 1. A method comprising the steps of: remove a firstvalve located on a tank car and replace the first valve with areplacement valve, wherein the replacement valve is installed in an openposition; insert a pressure test device into the replacement valve,wherein the pressure test device includes a pressure test valve cap witha test valve bladder located on a lower end of the replacement valve, abladder pressure fitting connected by a hose to the test valve bladderand connected through the pressure test valve cap, to inflate anddeflate the test valve bladder against a wall of a siphon pipe, and atest pressure fitting to pressurize the replacement valve to detect aleak in the replacement valve; apply the bladder pressure to the testpressure fitting and the test valve bladder to inflate the test valvebladder to tighten the test valve bladder against the wall of the siphonpipe; apply a test pressure through the pressure test valve cap; conducta bubble leak inspection of the replacement valve that includesutilizing a bubble liquid on the replacement valve, wherein if there isa leakage at the replacement valve, the bubble liquid will bubble at thereplacement valve and if there is no bubbling at the replacement valve,there is no leakage at the replacement valve; release the test pressure;deflate the test valve bladder; and remove the pressure test device. 2.The method of claim 1, further including the step of: insert and flownitrogen gas into the siphon pipe located on the tank car below thefirst valve.
 3. The method of claim 2, wherein the nitrogen gas isinserted and flowed into the siphon pipe for 60 seconds which creates abarrier to not allow toxic fumes to escape from the tank car.
 4. Themethod of claim 1, wherein the bladder pressure utilizes nitrogen gas.5. The method of claim 1, wherein the test pressure is 30 psig.
 6. Themethod of claim 1, wherein the test pressure is applied from a valvehose and a pressure regulator through the pressure test valve cap. 7.The method of claim 1, wherein the test pressure device includes a chainthat connects to the pressure test valve cap and the test valve bladderto ensure that the test valve bladder is not dropped in the tank car. 8.A method comprising the steps of: remove a valve located on a tank car,repair the valve, and reinstall the repaired valve, wherein the repairedvalve is installed in an open position; insert a pressure test deviceinto the repaired valve, wherein the pressure test device includes apressure test valve cap with a test valve bladder located on thepressure test valve cap, a bladder pressure fitting to inflate anddeflate the test valve bladder against a wall of the siphon pipe, and atest pressure fitting to pressurize the repaired valve, the testpressure fitting located on the pressure test valve cap; apply thebladder pressure to the bladder pressure fitting to inflate the testvalve bladder to tighten the test valve bladder against the wall of thesiphon pipe; apply a test pressure through the pressure test valve cap;conduct a bubble leak inspection of the repaired valve that includesutilizing a bubble liquid on the repaired valve, wherein if there is aleakage at the repaired valve, the bubble liquid will bubble at therepaired valve and if there is no bubbling at the repaired valve, thereis no leakage at the repaired valve; release the test pressure; deflatethe test valve bladder; and remove the pressure test device.
 9. Themethod of claim 8, wherein the bladder pressure is regulated to 40 psig.10. The method of claim 8, wherein the bladder pressure utilizesnitrogen gas.
 11. The method of claim 8, wherein the test pressure is 30psig.
 12. The method of claim 8, wherein the test pressure is appliedfrom a valve hose and a pressure regulator through the pressure testvalve cap.
 13. The method of claim 8, wherein the test pressure deviceincludes a chain that connects to the pressure test valve cap and thetest valve bladder to ensure that the test valve bladder is not droppedin the tank car.
 14. The method of claim 8, further including the stepof: insert and flow nitrogen gas into the siphon pipe located on thetank car below the first valve.
 15. The method of claim 8, wherein thenitrogen gas is inserted and flowed into the siphon pipe for 60 secondswhich creates a barrier to not allow toxic fumes to escape from the tankcar.